Types of Process control system

Types of Advanced Process Control

1. PROCESS CONTROL SYSTEM

2.  WHAT IS PROCESS?  WHAT IS CONTROL?  TYPES OF PROCESS  BASICS OF PROCESS CONTROL  PROCESS VARIABLE  PROCESS CONTROL SYSTEM  TYPES OF PCS  APPLICATION OF PCS CONTENT WHAT IS PROCESS? WHAT IS CONTROL? TYPES OF PROCESS PROCESS CONTROL PROCESS CONTROL SYSTEM(PCS) PROCESS VARIABLES COMPONENTS OF PCS PRIMARY DEVICES OF PCS TYPES OF PCS APPLICATION FUTURE SCOPE CONCLUSION REFERENCES

3. WHAT IS PROCESS? A sequence of interdependent and linked procedures At every stage it consume one or more type of resources (employee time, energy, machines, money etc.) into outputs These outputs then serve as inputs for the next stage until a known goal or end result is reached

4. What is control?  Control in process industries refers to the regulation of all aspects of the process.

5. TYPES OF PROCESS CONT I NUOUS PROCESS BATCH PRODUCTION INDIVIDUAL OR DISCRETE PRODUCTS PRODUCTION

6. TYPES OF PROCESSES  1.Continuous process- process itself runs continuously and uninterrupted in time. Example: Production of chemicals, plastics  2.Batch process- operation is performed on the batch to produce a finished product. Example: Production of adhesive and glues  3.Individual or discrete process- a series of operations produces a useful output product. Example: involves the production of discrete pieces of product such as metal stamping.

7. PROCESS CONTROL An engineering discipline that deals with architectures, mechanism and algorithms for maintaining the output of a specific process within a desired range’s extensively used in industry enables mass production of consistent products from continuously operated processes such as oil refining, paper manufacturing etc. enables automation by which a small staff of operating personnel can operate a complex process from a central control room.

8. WHY???? Manufacturers control the production process for three reasons: Reduce variability Increase efficiency Ensure safety

9. system A process control system an be defined as the functions and operations necessary to change material either physically or chemically. Process control normally refers to the manufacturing or processing of products in industry.

10. PROC E S S VARIABLES A condition of the process fluid (a liquid or gas) that can change the manufacturing process in some way. Common process variables include: Pressure Flow Level Temperature Density Liquid interface Mass Conductivity

11. Components of process control system Operator-machine interface operator E x ter n al sensors Proc e ss sensors Input signal condi- tio n i n g controller Outp u t Signal C o n d i - ti on i n g C o ntr o l l ed process External act u at o rs Process act u at o rs computer

12. Programmable logic control Distributed control system

13. PRIMARY DEVICES OF PCS- 1.Programmable Control Logic Best for controlling machines with several discrete devices such as motor starters, limit switches, etc Uses a programmable memory to store instructions and execute specific functions that include on/off control, timing, counting, sequencing, etc It is equipped with special input/output interfaces and a control programming language.

14. 2. DISTRIBUTED CONTROL SYSTEM Central control systems which are good at controlling analog devices. In this control elements are distributed throughout the system. A hierarchy of controllers is connected by communications networks for command and monitoring. Dedicated systems used to control manufacturing processes that are continuous or batch-oriented such as oil refining, petrochemicals, central station power generation, fertilizers etc.

15. open-loop control system closed loop control system TYPES OF PROCESS CONTROL SYSTEM

16. 1.Ope n l oop system A control action is applied on the output of the system It does not receive any feedback signal to control or alter the output status Set Point- Controller- Actuators- Process- Disturbance-

17. 2. C losed loop system the output of the process affects the input control signal. The system measures the actual output of the process and compares it to the desired output. Comparator- Error Amplifier Controller- Output attenuator- Sensor Feedback -

18. APPLICATIONS OF PCS  Food Production  Telecommunication and IT sector  Car wheel manufacturing process  Waste water treatment  Continuous filling operation

19. Future scope Advanced Process Control Improved process modelling technique, more capable performance monitoring tools will produce the “next” generation of PCS with greater economic benefits and improved reliability. Many automation projects will be implemented within the so called SMART CITY. In transportation, buildings, and health care will have closer proximity to process control system.

20. Advanced Process Control Advanced process control  (APC) refers to a broad range of techniques and technologies implemented within industrial process control systems. Advanced process controls are usually deployed optionally and in addition to  basic  process controls. Basic process controls are designed and built with the process itself, to facilitate basic operation, control and automation requirements. Process controls (basic as well as advanced) are implemented within the process control system, which may mean a  distributed control system (DCS) ,  programmable logic controller (PLC) , and/or a supervisory control computer. DCSs and PLCs are typically industrially hardened and fault-tolerant. Supervisory control computers are often not hardened or fault-tolerant, but they bring a higher level of computational capability to the control system, to host valuable, but not critical, advanced control applications. Advanced controls may reside in either the DCS or the supervisory computer, depending on the application. Basic controls reside in the DCS and its subsystems, including PLCs.

21. Types of Advanced Process Control Advanced regulatory control (ARC) refers to several proven advanced control techniques, such as override or adaptive gain (but in all cases, "regulating or feedback"). ARC is also a catch-all term used to refer to any customized or non-simple technique that does not fall into any other category. ARCs are typically implemented using function blocks or custom programming capabilities at the DCS level. In some cases, ARCs reside at the supervisory control computer level. Advanced process control (APC) refers to several proven advanced control techniques, such as feedforward , decoupling, and inferential control. APC can also include Model Predictive Control, described below. APC is typically implemented using function blocks or custom programming capabilities at the DCS level. In some cases, APC resides at the supervisory control computer level.

22. Types of Advanced Process Control Multivariable  Model predictive control  (MPC) is a popular technology, usually deployed on a supervisory control computer, that identifies important independent and dependent process variables and the dynamic relationships (models) between them, and often uses matrix-math based control and optimization algorithms to control multiple variables simultaneously. One requirement of MPC is that the models must be linear across the operating range of the controller. MPC has been a prominent part of APC ever since supervisory computers first brought the necessary computational capabilities to control systems in the 1980s. Nonlinear MPC: Similar to Multivariable MPC in that it incorporates dynamic models and matrix-math based control; however, it does not have the requirement for model linearity. Nonlinear MPC is capable of accommodating processes with models that have varying process gains and dynamics (i.e. dead-times and lag times).

23. Types of Advanced Process Control Intelligent control  is a class of  control  techniques that use various  artificial intelligence  computing approaches like  neural networks ,  Bayesian probability ,  fuzzy logic ,  machine learning ,  evolutionary computation  and  genetic algorithms .

24. Future scope Advanced Process Control Improved process modelling technique, more capable performance monitoring tools will produce the “next” generation of PCS with greater economic benefits and improved reliability. Many automation projects will be implemented within the so called SMART CITY. In transportation, buildings, and health care will have closer proximity to process control system.

25. CONCLUSION  PCS leads to automation in various fields of industry. It also provides more reliability and improvement in product. Lots of work can be done in single minute of time which reduces more time required for that work. It enables manufacturers to keep their operations running within specified limits and to set more precise limits to maximize profitability, ensure quality and safety.

26. REFERENCES  www.electroniceforyou.com  www.http.//.nibusinessinfo.com  www.IEEE.org  www.wikipedia.org

27. Presented by-  A.Arulkumar,AP /MTRE, Kamaraj College of Engineering and Technolgy